Protective Device with a Combined Mask and Face Shield

ABSTRACT

A protective device that includes a combined mask and face shield. The mask and face shield are attached together to form a continuous member that extends across the face of a user. A continuous seal extends around the exterior of the device including the mask and face shield.

CROSS-REFERENCE TO RELATED APPLICATIONS

This claims priority to U.S. Provisional Application No. 63/020,768 filed May 6, 2020 and which is hereby incorporated by reference in its entirety.

BACKGROUND

Masks and face shields are used for a variety of different purposes. One example is for protection from Covid 19 and its variants which are transmitted predominantly by respiratory droplets generated when people cough, sneeze, tank, breathe, etc. These protective devices act to protect the user by preventing the respiratory droplets from reaching the face of the user. The protective devices also protect others around the user by preventing the transmission of respiratory droplets from the user outward into their environment.

Masks and face shields are separate devices that are worn separately by the user. The mask is sized to fit over the mouth and nose of the user, and the face shield is sized to fit over at least the eyes of the user. When both devices are worn by the user, there can be a gap between the devices. This gap can lead to inadequate protection for the user.

Thus, there is a need for a combined mask and face shield that can be worn by a user.

SUMMARY

One aspect is directed to a protective device comprising a mask comprising an upper edge, lower edge, and opposing side edges. The mask is sized to extend over a nose and mouth of a user. A transparent face shield is connected to the upper edge of the mask and sized to extend upward from the mask and over eyes of the user. The face shield and the mask have different constructions. A seal is connected to and extends outward from inner surfaces of each of the mask and the face shield. The seal comprises a single continuous member that extends completely around an outer perimeter of the mask and face shield.

In another aspect, straps are connected to each of the mask and the face shield to attach to the user with the straps configured to apply a force to deform the seal against the user.

In another aspect, the straps comprise a first pair of ear straps attached to the side edges of the mask and a head band attached to side edges of the face shield.

In another aspect, an additional strap is attached to an upper edge of the face shield to maintain a section of the seal that extends along the upper edge of the face shield in contact with a face of the user.

In another aspect, the upper edge of the mask overlaps a lower edge of the face shield.

In another aspect, an intermediate seal extends between opposing sides of the outer perimeter of the mask and the face shield at the overlap with the seal configured to prevent air that is exhaled into the mask from contacting the inner surface of the face shield.

In another aspect, the intermediate seal comprises a first end connected to the seal at a first opposing side and a second end connected to the seal at a second opposing side.

In another aspect, a deformable wire is connected to mask and configured to be positioned at the nose of the user, the wire positioned below the overlap and away from the face shield.

In another aspect, the intermediate seal and the seal comprise the same construction.

In another aspect, the seal is positioned away from the outer surface of the mask and the face shield.

One aspect is directed to a protective device to protect a user. The protective device comprises a face covering sized to extend across a face of the user and comprising and inner surface that faces towards the user and an opposing outer surface that faces away from the user. The face covering is solid without gaps and further comprises: an opaque mask that forms a lower section of the face covering; and a transparent face shield that is attached to the mask and that forms an upper section of the face covering. Each of the mask and the face shield comprise a lower edge, an upper edge, and side edges. The upper edge of the mask is attached to the lower edge of the face shield. An outer perimeter is formed by the upper edge of the face shield, the lower edge of the mask, and the side edges of both of the mask and the face shield. A seal is connected to the inner surface of the face covering with the seal extending continuously around the outer perimeter of the face covering.

In another aspect, a width of the mask at the upper edge is equal to a width of the face shield at the lower edge.

In another aspect, a first pair of ear straps is attached to the side edges of the mask, and a head band is attached to side edges of the face shield.

In another aspect, the upper edge of the mask overlaps a lower edge of the face shield.

In another aspect, an intermediate seal extends across the face covering at a connection point where the face shield and the mask are connected together with the seal configured to prevent air that is exhaled from the user from contacting the inner surface of the face shield.

In another aspect, the intermediate seal comprises a first end connected to the seal at a first opposing side and a second end connected to the seal at a second opposing side with the intermediate seal and the seal having a common construction.

One aspect is directed to a method of using a protective device to protect a user. The method comprises: positioning a single piece face covering over a face of the user with the face covering comprising a transparent face shield and an opaque mask; aligning the face shield over eyes of the user; aligning the mask over a nose and a mouth of the user; positioning an intersection line across a face of the user between the eyes and the nose with the intersection line formed by the connection between the face shield and the mask; positioning a continuous seal that extends completely around a perimeter of the face covering against the face of the user; and applying a holding force to the face covering and deforming the seal against the face of the user and sealing the face covering against the face of the user.

The various aspects of the various embodiments may be used alone or in any combination, as is desired.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a protective device.

FIG. 2 is a rear view of a protective device.

FIG. 3 is a schematic side view of a mask connected to a face shield.

FIG. 4 is a schematic side view of a mask and face shield connected at an intermediate member.

FIG. 5 is a section view cut along line V-V of FIG. 2.

FIG. 6 is a perspective view of a protective device attached to a user.

FIG. 7 is a section view cut along line VII-VII of FIG. 6.

FIG. 8 is a flowchart diagram of a method of using a protective device.

DETAILED DESCRIPTION

The present application is directed to a protective device that includes a combined mask and face shield. The mask and face shield are attached together to form a continuous member without gaps that extends across the face of a user. A continuous seal extends around the exterior of the device that is formed by the mask and face shield.

FIG. 1 illustrates the protective device 10 with a face covering 29 sized to extend across the face of a user. The protective device 10 includes the mask 20 sized to extend across the mouth and nose of the user. The face shield 30 is attached to the top edge of the mask 20 and is sized to extend across the eyes of the user. In one example, the face covering 29 is constructed without gaps.

The mask 20 is configured to reduce exposure to one or more respiratory droplets, large particles, and aerosols. The mask 20 can include a variety of different shapes and sizes that extend over the mouth and nose of the user. FIG. 1 includes an example with the mask 20 having an upper edge 21, lower edge 22, and side sides 23, 24.

The mask 20 can be made from a variety of different materials, including but not limited to cloth, and various synthetic materials. In one example, the mask 20 is made from multiple layers of fabric, including one or more layers include an absorbent material such as cotton, and non-woven non-absorbent materials such as polypropylene, polyester, and polyester blends. In one example, the mask 20 is a N95 respirator. In one example, the mask 20 is a N95 respirator that includes a valve. In one example, the mask 20 is a standard surgical mask. In one example, the mask 20 includes an anti-microbial material. In one example, the mask 20 is constructed from synthetic polymer fibers. In one specific example, the mask 20 is constructed from nonwoven polypropylene fabric.

The face shield 30 is attached at the upper edge 21 of the mask 20. The face shield 30 includes an upper edge 31, a lower edge 32, and opposing side edges 33, 34. The face shield 30 comprises a fluid-impervious, transparent material that protects the eyes and face of the user. The face shield 30 is constructed from a transparent material to allow for the user to see through. The face shield 30 can be constructed from a variety of materials, including but not limited to plastics. The face shield 30 can be treated with an anti-fog material to prevent fogging when worn by the user.

The mask 20 and face shield 30 can be constructed from various materials. In one example, the mask 20 is opaque. In another example, the mask 20 is transparent. In one example, the mask 20 and face shield 30 are constructed from different materials.

Each of the mask 20 and face shield 30 have a width W measured between the opposing side edges 23, 24, 33, 34 respectively. In one example as illustrated in FIGS. 1 and 2, the width W of the mask 20 at the upper edge 21 is the same as the width W of the face shield 30 at the lower edge 32. This equal sizing provides for a uniform transition between the mask 20 and the face shield 30.

The mask 20 and face shield 30 can be connected together in various manners. In one example as illustrated in FIG. 3, the mask 20 and face shield 30 overlap. The overlapping sections are connected together by one or more mechanical fasteners and/or adhesive. In another example as illustrated in FIG. 4, the mask 20 and face shield 30 are attached to an intermediate seal 40. In one example with an intermediate seal 40, the mask 20 and face shield 30 do not overlap.

The seal 40 extends around the mask 20 and face shield 30. The seal 40 contacts against the user and forms a barrier that prevents passage of respiratory droplets, large particles, and aerosols. In one example, the seal 40 is a single continuous piece. FIGS. 1 and 2 illustrate an example in which the seal 40 is a single continuous member that extends around the perimeter of each of the mask 20 and face shield 30. The continuous structure prevents a gap that could be formed between sections of the seal 40 that could allow potentially harmful materials to pass to the user. In another example, the seal 40 is formed from two or more separate sections that each form a section of the overall seal 40. The sections abut together to form the seal 40 around the perimeter.

The seal 40 is attached to each of the mask 20 and the face shield 30. The seal 40 can be attached to one or both of the inner surface 25 and perimeter edge 26 of the mask 20, and the inner surface 35 and perimeter edge 36 of the face shield 30. FIG. 5 illustrates an example with the seal 40 extending outward beyond the perimeter edge 36 and the inner surface 35 of the face shield 30.

The seal 40 extends outward from the inner surface 36 of the face shield 30 and inner surface 20 of the mask 20 to contact against the face of the user. This positioning provides for the seal 40 to make contact with and form a seal against the face of the user. In one example, the seal 40 has a deformable construction that compresses when the protective device 10 is attached to the user and a force applied by one or more straps 50.

The seal 40 can be attached in a variety of different manners. In one example, the seal 40 is attached with an adhesive. In another example, the seal 40 is stitched onto the mask 20 and face shield 30.

The seal 40 can be constructed from a variety of different materials. Examples include but are not limited to latex, rubber, cloth, mesh, and various combinations. In one example, the seal 40 is hypoallergenic to prevent an allergic reaction due to be in contact with the face of the user. The seal 40 is deformable to change shape when applied against the face of the user and held in position by the straps 50. In one example, the One or more straps 50 extend from the protective device 10 to connect to the user and maintain the position across the face of the user. In one example, the straps 50 includes a pair of opposing ear straps each configured to wrap around an ear of the user. Straps 50 can also include a head strap 50 that extends around the head of the user. In another example, one or more straps 50 extend from the upper edge 31 of the face shield 30. The straps 50 can be constructed from an flexible material such as natural and synthetic rubber that stretches and returns towards its original size to apply a force to maintain the protective device 10 on the user.

In one example as illustrated in FIG. 6, multiple straps 50 are used to attach the device 10 to the user. A first set of straps 50 are configured to attached around the user's ears. A second strap 50 is a head strap 50 that extends from the face shield 30 and extends around the head of the user. A third strap 50 extends from the top edge of the face shield 30 to extend over the head of the user and attach to the second strap 50. The straps 50 provide for the device 10 to lay flat against the user's face to prevent gaps in the seal 40 that could provide for ingress and/or egress of potentially harmful aspects.

The seal 40 extends outward from the inner surfaces 25, 35 of the mask 20 and face shield 30 to form a barrier against the face of the user. The one or more straps 50 apply a force to the protective device 10 to deform the seal 40 to form the barrier that prevents passage of air.

FIG. 6 illustrates the protective device 10 positioned on a user. The mask 20 extends across the nose and mouth and the face shield 30 extends across the eyes. Straps 50 hold the device 10 against the face of the user. In this example, a first set of straps 50 extend around the user's ears and a second strap 50 extends around the user's head. The straps 50 apply a force to pull the device 10 against the face of the user in the direction of arrow A. This force maintains the seal 40 against the user's face and prevents openings.

As illustrated in FIG. 6, the upper edge of the face shield 30 contacts against the face of the user in proximity to the user's hairline. The width of the device 10 also provides for the lateral edges to contact the user's face in proximity to the ears. This sizing provides for the majority or entirety of the user's face to be covered by the device 10.

As illustrated in FIG. 7, the seal 40 extends outward from the inner surface of the protective device 10. This positioning provides for the seal 40 to contact against the face of the user. The seal 40 deforms because of the force A applied by the straps 50. This deformation increases contact against the user's face and prevents openings. When the device 100 is removed, the seal 40 returns towards its original shape and size for subsequent use.

An intermediate member 60 extends across the face covering 29. As illustrated in FIGS. 1 and 2, the intermediate member 60 includes a first end 61 positioned at the first side edge and a second end 62 positioned at a second side edge. In one example, the intermediate member 60 forms a seal across the face of the user. The intermediate member 60 prevents air that is exhaled from the user to enter into the upper section of the face covering 29 that is formed by the face shield 30.

In one example, the intermediate member 60 has the same construction as the seal 40. The intermediate member 60 extends outward beyond the inner surface of the face covering 29 to contact against the face of the user and form a seal. Each of the first and second ends 61, 62 are connected to the seal 40. The connections prevent gaps from being formed between the seal 40 and the intermediate member 60.

FIG. 8 illustrates a method of using a protective device 10 to protect a user. The method includes positioning a single piece face covering 29 over a face of the user with the face covering 29 comprising a transparent face shield 30 and an opaque mask 20 (block 300). The face shield 30 is aligned over the eyes of the user (block 302) and the mask 20 is aligned over the nose and mouth of the user (block 304). An intersection line 60 is positioned across a face of the user between the eyes and the nose with the intersection line 60 formed by the connection between the face shield 30 and the mask 20 (block 306). A continuous seal 40 that extends completely around a perimeter of the face covering 29 is positioned against the face of the user (block 308). A holding force is applied to the face covering 29 and deforms the seal 40 against the face of the user and seals the face covering 29 against the face of the user (block 310).

A deformable wire 99 can be attached to the mask 20. The wire 99 can be deformed to conform to the shape and size of the user's nose. The wire 99 is positioned below the intermediate line 60.

The device 10 can be used for a wide variety of applications. One application includes for use in protecting the user from Covid. Another application provides for protecting the user from various bodily fluids such as but not limited to blood splatter and saliva, such as could be applicable for medical use.

In one example, the device 10 is constructed from fairly inexpensive materials such that it is disposable after being worn by the user. In another example, the device 10 is constructed from materials that can be washed/cleaned for repeated wear by the user.

Spatially relative terms such as “under”, “below”, “lower”, “over”, “upper”, and the like, are used for ease of description to explain the positioning of one element relative to a second element. These terms are intended to encompass different orientations of the device in addition to different orientations than those depicted in the figures. Further, terms such as “first”, “second”, and the like, are also used to describe various elements, regions, sections, etc and are also not intended to be limiting. Like terms refer to like elements throughout the description.

As used herein, the terms “having”, “containing”, “including”, “comprising” and the like are open ended terms that indicate the presence of stated elements or features, but do not preclude additional elements or features. The articles “a”, “an” and “the” are intended to include the plural as well as the singular, unless the context clearly indicates otherwise.

The present invention may be carried out in other specific ways than those herein set forth without departing from the scope and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein. 

What is claimed is:
 1. A protective device comprising: a mask comprising an upper edge, lower edge, and opposing side edges, the mask sized to extend over a nose and mouth of a user; a transparent face shield connected to the upper edge of the mask and sized to extend upward from the mask and over eyes of the user, the face shield and the mask having different constructions; and a seal connected to and extending outward from inner surfaces of each of the mask and the face shield, the seal comprising a single continuous member that extends completely around an outer perimeter of the mask and face shield.
 2. The protective device of claim 1, further comprising straps connected to each of the mask and the face shield to attach to the user, the straps configured to apply a force to deform the seal against the user.
 3. The protective device of claim 2, wherein the straps comprise a first pair of ear straps attached to the side edges of the mask and a head band attached to side edges of the face shield.
 4. The protective device of claim 3, further comprising an additional strap attached to an upper edge of the face shield to maintain a section of the seal that extends along the upper edge of the face shield in contact with a face of the user.
 5. The protective device of claim 1, wherein the upper edge of the mask overlaps a lower edge of the face shield.
 6. The protective device of claim 5, further comprising an intermediate seal that extends between opposing sides of the outer perimeter of the mask and the face shield at the overlap, the seal configured to prevent air that is exhaled into the mask from contacting the inner surface of the face shield.
 7. The protective device of claim 6, wherein the intermediate seal comprises a first end connected to the seal at a first opposing side and a second end connected to the seal at a second opposing side.
 8. The protective device of claim 5, further comprising a deformable wire connected to mask and configured to be positioned at the nose of the user, the wire positioned below the overlap and away from the face shield.
 9. The protective device of claim 6, wherein the intermediate seal and the seal comprise the same construction.
 10. The protective device of claim 1, wherein the seal is positioned away from the outer surface of the mask and the face shield.
 11. A protective device to protect a user, the protective device comprising: a face covering sized to extend across a face of the user and comprising and inner surface that faces towards the user and an opposing outer surface that faces away from the user, the face covering being solid without gaps and further comprising: an opaque mask that forms a lower section of the face covering; a transparent face shield that is attached to the mask and that forms an upper section of the face covering; each of the mask and the face shield comprising a lower edge, an upper edge, and side edges; the upper edge of the mask being attached to the lower edge of the face shield; an outer perimeter formed by the upper edge of the face shield, the lower edge of the mask, and the side edges of both of the mask and the face shield; and a seal connected to the inner surface of the face covering, the seal extending continuously around the outer perimeter of the face covering.
 12. The protective device of claim 11, wherein a width of the mask at the upper edge is equal to a width of the face shield at the lower edge.
 13. The protective device of claim 11, further comprising a first pair of ear straps attached to the side edges of the mask, and a head band attached to side edges of the face shield.
 14. The protective device of claim 11, wherein the upper edge of the mask overlaps a lower edge of the face shield.
 15. The protective device of claim 11, further comprising an intermediate seal that extends across the face covering at a connection point where the face shield and the mask are connected together, the seal configured to prevent air that is exhaled from the user from contacting the inner surface of the face shield.
 16. The protective device of claim 15, wherein the intermediate seal comprises a first end connected to the seal at a first opposing side and a second end connected to the seal at a second opposing side with the intermediate seal and the seal having a common construction.
 17. A method of using a protective device to protect a user, the method comprising: positioning a single piece face covering over a face of the user with the face covering comprising a transparent face shield and an opaque mask; aligning the face shield over eyes of the user; aligning the mask over a nose and a mouth of the user; positioning an intersection line across a face of the user between the eyes and the nose with the intersection line formed by the connection between the face shield and the mask; positioning a continuous seal that extends completely around a perimeter of the face covering against the face of the user; and applying a holding force to the face covering and deforming the seal against the face of the user and sealing the face covering against the face of the user. 